BATTERY CUSHION PAD AND MOLDING METHOD, AND BATTERY MODULE AND MOLDING METHOD

Abstract

 This application discloses a battery cushion and a forming method thereof, and a battery module and a forming method thereof. The battery cushion includes a body and collapsible pores. The collapsible pores are disposed in the body. The collapsible pores include at least a first pore and a second pore. A collapsing pressure of the first pore is less than a collapsing pressure of the second pore, so that the battery cushion can release a compression space in a terraced manner under different extrusion forces. The battery cushion disclosed in this application can not only achieve a pre-tightening force required during assembly of the battery module but also effectively relieve an expansive force generated during working of the battery module.

Description

[0001] This application claims priority to Chinese Patent Application No. 201821712200.X, filed with the Chinese Patent Office on October 22, 2018 and entitled "BATTERY CUSHION AND BATTERY MODULE", which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] This application relates to the technical field of batteries, and in particular, to a battery cushion and a battery module.

BACKGROUND

[0003] A battery module generally includes multiple cells. During assembly of the battery module, a pre-tightening force is required in the battery module to firmly fasten the cells and ensure good contact of a reaction interface of the cells. A battery cushion generally needs to be arranged in the battery module. The pre-tightening force required in the battery module is achieved by using a reaction force generated by compressing the battery cushion.

[0004] In addition, during operation of the battery module, the cells keep expanding. Consequently, the battery cushion keeps being compressed, the reaction force generated by the battery cushion keeps increasing, and a large expansive force is generated in the battery module, so that the battery module is likely to fail and a service life of the battery module is affected.

[0005] Therefore, it is necessary to develop a battery cushion that can not only achieve the pre-tightening force required during assembly of the battery module but also effectively relieve the expansive force generated during working of the battery module.

SUMMARY

[0006] An objective of this application is to disclose a battery cushion and a forming method thereof, and a pouch-type cell battery module and a forming method thereof to not only achieve a pre-tightening force required during assembly of the battery module but also effectively relieve an expansive force generated during working of the battery module.

[0007] A first aspect of this application discloses a battery cushion, including:

a body; and

collapsible pores, disposed in the body, where the collapsible pores include at least a first pore and a second pore, a collapsing pressure of the first pore is less than a collapsing pressure of the second pore, so that the battery cushion can release a compression space in a terraced manner under different extrusion forces.

[0008] Optionally, a diameter of the first pore is greater than a diameter of the second pore.

[0009] Optionally, a diameter of each collapsible pore is 10 µm to 1 mm.

[0010] Optionally, a lower-limit thickness of a wall of the first pore is less than a lower-limit thickness of a wall of the second pore.

[0011] Optionally, a thickness of a wall of each collapsible pore is 1 µm to 0.3 mm.

[0012] Optionally, the collapsible pores are uniformly distributed in the body, and a percentage of a volume of the collapsible pores in a volume of the body is 40% to 90%.

[0013] Optionally, a connected pore is further disposed in the body, and the connected pore has a vent and communicates with the outside of the body through the vent.

[0014] Optionally, the body is made of an elastic insulating material, and the body is of a flat structure.

[0015] Optionally, a thickness of the body is 0.5 mm to 20 mm.

[0016] A second aspect of this application discloses a pouch-type cell battery module, including:

at least two pouch-type cells, arranged in sequence along a thickness direction of the pouch-type cells; and

a battery cushion, where the battery cushion is any battery cushion disclosed in this application, is disposed between the pouch-type cells; and

the pouch-type cells press the battery cushion tightly.

[0017] A third aspect of this application discloses a battery cushion forming method, including:
forming collapsible pores in a body by controlling a foaming process, where the collapsible pores include at least a first pore and a second pore, a collapsing pressure of the first pore is less than a collapsing pressure of the second pore, so that the battery cushion can release a compression space in a terraced manner under different extrusion forces.

[0018] Optionally, the forming collapsible pores in a body by controlling a foaming process includes:
controlling the foaming process so that the first pore and the second pore are uniformly distributed in a longitudinal section of the body and a cross section of the body.

[0019] A fourth aspect of this application discloses a battery module forming method, including:
pressing a battery cushion tightly with pouch-type cells, where the battery cushion is formed by using the battery cushion forming method disclosed in this application.

[0020] Optionally, the pressing a battery cushion tightly with pouch-type cells includes:

arranging the pouch-type cells in sequence along a thickness direction of the pouch-type cells; and

disposing the battery cushion between the pouch-type cells.

[0021] The technical solutions disclosed in this application achieve the following beneficial effects:

[0022] The collapsible pores are disposed in the body of the battery cushion disclosed in this application. The collapsible pores include at least the first pore and the second pore. The collapsing pressure of the first pore is less than the collapsing pressure of the second pore. In a case that the cells expand during working, the battery cushion is compressively deformed. As the battery cushion keeps being compressed, the expansive force in the battery module keeps increasing. In a case that the expansive force in the battery module reaches the collapsing pressure of the first pore, the first pore is collapsed and releases a compression space to reduce the expansive force in the battery module. The second pore refrains from collapsing so as to maintain the pre-tightening force in the battery module.

[0023] Understandably, the above general description and the following detailed description are only exemplary without limiting this application.

DESCRIPTION OF DRAWINGS

[0024] 

FIG 1 is a schematic structural diagram of a battery module according to this application;

FIG 2 is a schematic exploded view of a module cell shown in FIG 1; and

FIG 3 is a schematic cross-sectional view of a battery cushion according to this application.

Reference numerals:

[0025] 

1: Module cell;

10: Battery cushion;

100: Body;

102: Collapsible pores;

1020: First pore;

1022: Second pore;

104: Connected pore;

12: Fastening framework;

120: Cell accommodation cavity;

14: Pouch-type cell;

16: Thermally conductive plate;

2: Outer metal frame;

3: Wire harness separator; and

4: End plate.

[0026] The drawings described here are incorporated into the specification as a part of the specification. The drawings illustrate embodiments of this application and are used together with the specification to explain the principles of this application.

DESCRIPTION OF EMBODIMENTS

[0027] The following describes this application in further detail with reference to specific embodiments and accompanying drawings.

[0028] The words of direction such as "on", "above", "under", "below", "left", and "right" described in the embodiments of this application are described from a perspective shown in the drawings, and shall not be understood as a limitation on the embodiments of this application. In addition, understandably, depending on the context, one element mentioned as being connected "on" or "under" another element not only means that the element may be directly connected "on" or "under" the other element, but also means that the element may be indirectly connected "on" or "under" the other element through an intermediate element.

[0029] As shown in FIG 1 to FIG. 3, a battery module disclosed in an embodiment of this application includes at least two (multiple) pouch-type cells 14 and a battery cushion 10. The pouch-type cells 14 are arranged in sequence along a thickness direction of the pouch-type cells. The battery cushion 10 is disposed between the pouch-type cells 14, and the pouch-type cells 14 press the battery cushion 10 tightly so that the pouch-type cells 14 meet a preset pre-tightening force requirement. In a case that the battery module expands during working, the battery cushion 10 can release a compression space to effectively relieve an expansive force within the battery module.

[0030] The battery module may further include an outer metal frame 2. The outer metal frame 2 is configured as a U-shaped structure. Each of two sidewalls of the outer metal frame 2 is in contact with two ends that are of the battery module and that are in the thickness direction of the pouch-type cells 14. Therefore, the multiple pouch-type cells 14 and the battery cushion 10 can press each other tightly to meet the pre-tightening force requirement within the battery module and prevent the battery module from loosening. An end plate 4 may be disposed at each of the two ends of the U-shaped structure (the two ends along a length direction of the pouch-type cells 14). The end plate 4 is welded to each of the two ends of the U-shaped structure, and forms, together with the U-shaped structure, a casing of the battery module to protect the battery module on the whole. The multiple pouch-type cells 14 may be electrically connected through a wire harness separator 3.

[0031] As shown in FIG 2, the battery module disclosed in this application may further include a fastening framework 12. The fastening framework 12, the battery cushion 10, and the pouch-type cells 14 constitute a module cell, thereby simplifying assembly of the battery module and fastening the pouch-type cells 14 and the battery cushion 10 more firmly. The battery cushion 10 is disposed in the fastening framework 12, and divides the fastening framework 12 into at least two cell accommodation cavities 120 along a thickness direction of the fastening framework. The pouch-type cells 14 are disposed in the cell accommodation cavities 120, and press the battery cushion 10 tightly. The pouch-type cells 14 on both sides of the battery cushion 10 can share one battery cushion 10, thereby reducing the quantity of battery cushions 10, reducing the size of the battery module, and increasing an energy density of the battery module.

[0032] Further, the module cell 1 may further include a thermally conductive plate 16. The thermally conductive plate 16 may be a metal plate of high thermal conductivity, such as an aluminum plate. The thermally conductive plate 16 is disposed on one side of the pouch-type cell 14 away from the battery cushion 10, so as to reduce a temperature on one side of the pouch-type cell 14 away from the battery cushion 10 and control the pouch-type cell 14 to expand toward a center location of the fastening framework 12.

[0033] As shown in FIG. 3, the battery cushion 10 disclosed in this application includes a body 100 and collapsible pores 102. The collapsible pores 102 are disposed in the body 100. During assembly of the battery module, the battery cushion 10 is compressively deformed to meet the pre-tightening force requirement in the battery module. During working of the battery module, the cells expand and the battery cushion 10 keeps being compressed. Under an extrusion force, the collapsible pores 102 can be collapsed and release the compression space to effectively relieve the expansive force in the battery module. The collapsible pores 102 include at least a first pore 1020 and a second pore 1022. A collapsing pressure of the first pore 1020 is less than a collapsing pressure of the second pore 1022, so that the battery cushion 10 releases the compression space in a terraced manner according to different extrusion forces. In other words, as the battery cushion 10 keeps being compressed, the expansive force in the battery module keeps increasing, the first pore 1020 is collapsed first and releases the compression space to reduce the expansive force in the battery module. The second pore 1022 refrains from collapsing so as to maintain the pre-tightening force in the battery module and effectively extend a service life of the battery module. Understandably, the battery cushion 10 may have a variety of collapsible pores 102 that collapse under different collapsing pressures, thereby forming more terraces, releasing the compression space hierarchically, and better adapting to expansive forces in the battery module.

[0034] Further, the collapsible pores 102 may include at least two types of pores that have different diameters. The first pore 1020 has a greater diameter, collapses under a lower collapsing pressure, and provides a larger compression space. In a case of collapsing, the first pore 1020 releases a larger compression space, and effectively reduces the expansive force in the battery module. The second pore 1022 has a smaller diameter, collapses under a higher collapsing pressure, and provides a smaller compression space and a greater reaction force to maintain the pre-tightening force in the battery module after the first pore 1020 is collapsed, thereby meeting both the compression space requirement and the pre-tightening force requirement of the pouch-type cells.

[0035] Exemplarily, diameters of the collapsible pores 102 are 10 µm to 1 mm, so that the collapsible pores are easy to implement and can meet the compression space requirement and the pre-tightening force requirement. Within such a range, the diameters of the collapsible pores 102 may be reasonably distributed in at least two sections, and two adjacent sections may be continuous or spaced apart from each other. Exemplarily, two adjacent sections are spaced apart from each other (for example, the diameter of the first pore 1020 is 10 µm to 300 µm, and the diameter of the second pore 1022 is 500 µm to 1 mm), so that the collapsing pressure of the first pore 1020 is obviously different from the collapsing pressure of the second pore 1022.

[0036] Further, the collapsible pores 102 may include at least two types of pores whose walls have different lower-limit thicknesses. The wall of the first pore 1020 has a smaller lower-limit thickness and collapses under a lower collapsing pressure. The wall of the second pore 1022 has a greater lower-limit thickness and collapses under a higher collapsing pressure. The thickness of the wall of a collapsible pore 102 is not uniform, and the collapsible pore 102 generally collapses at a fragile position where the wall is the thinnest. Therefore, terraced collapse can be implemented by configuring different lower-limit thicknesses of the walls of the collapsible pores 102. By controlling the lower-limit thicknesses of the walls of the collapsible pores 102, the terraced collapse of the collapsible pores 102 is easier to control and operate.

[0037] In a case that the lower-limit thickness of the wall of a collapsible pore 102 is too small, the collapsible pore 102 is likely to collapse under the pre-tightening force and fails. In a case that the lower-limit thickness of the wall of the collapsible pore 102 is too great, the collapsible pore 102 is not likely to collapse even under a large extrusion force and loses a cushioning effect. Therefore, exemplarily, the lower-limit thickness of the wall of the collapsible pores 102 according to this embodiment is 1 µm to 0.3 mm.

[0038] Further, the collapsible pores 102 are uniformly distributed in the body 100, and specifically but without limitation, uniformly distributed in a longitudinal section of the body 100 (the section along a thickness direction of the body 100) and uniformly distributed in a cross section of the body 100 (the section along an extension direction of the body 100). In this way, the battery cushion 10 has exactly the same compression performance in any direction, the battery cushion 10 can be uniformly compressed, a reliable contact is achieved between a side of each pouch-type cell 14 and the battery cushion 10 to prevent tilting, and a good contact of a reaction interface of the cells is ensured.

[0039] Specifically, in a case that the collapsible pores 102 include a first pore 1020 and a second pore 1022, the first pore 1020 and the second pore 1022 are uniformly mixed and uniformly distributed in the body 100. That is, the first pore 1020 and the second pore 1022 are not hierarchical. This implementation is easy to operate and achieves exactly the same compression performance of the battery cushion 10 everywhere in a thickness direction of the battery cushion.

[0040] Optionally, the first pore 1020 and the second pore 1022 may be disposed hierarchically (along the thickness direction of the battery cushion 10), and the first pore 1020 and the second pore 1022 are uniformly distributed each in a corresponding layer. In this way, the battery cushion 10 can release the compression space hierarchically, and the battery cushion 10 can be uniformly compressed.

[0041] Exemplarily, a percentage of a volume of the collapsible pores 102 in a volume of the body 100 is 40% to 90%, so that the battery cushion 10 has both high compression performance and resilience.

[0042] Specifically, the diameter and the wall thickness of the pores may be controlled by controlling a foaming process, for example, by controlling a foaming temperature, the quantity of a foaming agent, and a foaming time.

[0043] Further, a connected pore 104 may be disposed in the body 100. The connected pore 104 has a vent and communicates with the outside of the body 100 through the vent. The connected pore 104 does not form a closed space, and therefore, the connected pore 104 will not collapse under an extrusion force, so that the battery cushion 10 is always resilient to ensure a reliable pre-tightening force in the battery module.

[0044] Further, the body 100 is made of an elastic insulating material, and the body 100 is of a flat structure to form a steady contact support for the pouch-type cells 14 and prevent damage to the pouch-type cells 14 or deformation of a surface of the pouch-type cells 14. Specifically, the elastic insulating material may include rubber, silicon foam, polyurethane foam, and the like.

[0045] Exemplarily, a thickness of the body 100 is 0.5 mm to 20 mm. In this way, after the pouch-type cells 14 press the battery cushion 10 tightly, the battery cushion 10 can provide a pre-tightening force for the pouch-type cells 14 and still retain a compression space.

[0046] An embodiment of this application further discloses a battery cushion forming method, including:
forming collapsible pores in a body by controlling a foaming process, where the collapsible pores include at least a first pore and a second pore, a collapsing pressure of the first pore is less than a collapsing pressure of the second pore, so that the battery cushion can release a compression space in a terraced manner under different extrusion forces.

[0047] Optionally, the forming collapsible pores in a body by controlling a foaming process includes:
controlling the foaming process so that the first pore and the second pore are uniformly distributed in a longitudinal section of the body and a cross section of the body.

[0048] An embodiment of this application further discloses a battery module forming method, including:
pressing a battery cushion tightly with pouch-type cells, where the battery cushion is formed by using the battery cushion forming method disclosed in any embodiment of this application.

[0049] Optionally, the pressing a battery cushion tightly with pouch-type cells includes:

arranging the pouch-type cells in sequence along a thickness direction of the pouch-type cells; and

disposing the battery cushion between the pouch-type cells.

[0050] The foregoing descriptions are merely exemplary embodiments of this application, but are not intended to limit this application. A person skilled in the art understands that this application may have various modifications and variations. Any modification, equivalent replacement, improvement, and the like made without departing from the spirit and principles of this application shall fall within the protection scope of this application.

Claims

1. A battery cushion, comprising:

a body; and

collapsible pores, disposed in the body, wherein the collapsible pores comprise at least a first pore and a second pore, a collapsing pressure of the first pore is less than a collapsing pressure of the second pore, so that the battery cushion can release a compression space in a terraced manner under different extrusion forces.

2. The battery cushion according to claim 1, wherein a diameter of the first pore is greater than a diameter of the second pore.

3. The battery cushion according to claim 2, wherein a diameter of each collapsible pore is 10 µm to 1 mm.

4. The battery cushion according to claim 1, wherein a lower-limit thickness of a wall of the first pore is less than a lower-limit thickness of a wall of the second pore.

5. The battery cushion according to claim 4, wherein a thickness of a wall of each collapsible pore is 1 µm to 0.3 mm.

6. The battery cushion according to claim 1, wherein the collapsible pores are uniformly distributed in the body, and a percentage of a volume of the collapsible pores in a volume of the body is 40% to 90%.

7. The battery cushion according to any one of claims 1 to 6, wherein a connected pore is further disposed in the body, and the connected pore has a vent and communicates with the outside of the body through the vent.

8. The battery cushion according to any one of claims 1 to 6, wherein the body is made of an elastic insulating material, and the body is of a flat structure.

9. The battery cushion according to any one of claims 1 to 6, wherein a thickness of the body is 0.5 mm to 20 mm.

10. A battery module, comprising:

at least two pouch-type cells, arranged in sequence along a thickness direction of the pouch-type cells; and

a battery cushion, wherein the battery cushion is the battery cushion according to any one of claims 1 to 9, is disposed between the pouch-type cells; and

the pouch-type cells press the battery cushion tightly.

11. A battery cushion forming method, comprising:
forming collapsible pores in a body by controlling a foaming process, wherein the collapsible pores comprise at least a first pore and a second pore, a collapsing pressure of the first pore is less than a collapsing pressure of the second pore, so that the battery cushion can release a compression space in a terraced manner under different extrusion forces.

12. The forming method according to claim 11, wherein the forming collapsible pores in a body by controlling a foaming process comprises:
controlling the foaming process so that the first pore and the second pore are uniformly distributed in a longitudinal section of the body and a cross section of the body.

13. A battery module forming method, comprising:
pressing a battery cushion tightly with pouch-type cells, wherein the battery cushion is formed by using the battery cushion forming method according to any one of claims 11 to 12.

14. The forming method according to claim 13, wherein the pressing a battery cushion tightly with pouch-type cells comprises:

arranging the pouch-type cells in sequence along a thickness direction of the pouch-type cells; and

disposing the battery cushion between the pouch-type cells.

Drawing